Multi-stage forging process

ABSTRACT

A method of manufacturing a forged iron type golf club head with a cavity. The method of manufacturing comprises forming a billet into an intermediate club head body with a strike face comprising an upper region and a lower region; hot pressing a cavity into the rear portion of the intermediate body; and bending the strike face of the intermediate club head body to form a golf club head with a cavity and a planar strike face. Other embodiments are disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 16/573,938,filed on Sep. 17, 2019, now U.S. Pat. No. 11,273,486, issued on Mar. 15,2022, which claims the benefit of U.S. Provisional Patent Appl. No.62/732,438, filed on Sep. 17, 2018, the contents of all of which areincorporated fully herein by reference.

TECHNICAL FIELD

This disclosure relates generally to golf clubs and relates moreparticularly to a method of manufacturing a forged iron with a cavity.

BACKGROUND

In general, iron type golf club heads can be made by a variety ofmethods such as casting, co-casting, metal injection molding, machinemilling, and forging. Many iron type golf club heads contain cavities orfilling features to adjust the performance features of the golf clubhead when it strikes a golf ball. Often times, irons that containcavities are casted or co-casted, in order to achieve these advancedgeometries. Milling techniques are used to create club heads withcavities from a single block of material, however this is an expensiveand timely process. Further, forging techniques are often used to createan iron golf club head that is formed of an integral block of material.Forging is cheaper and quicker than milling, however the geometries thatcan be achieved are limited. With current industry techniques, it isdifficult to quickly and cheaply create a forged iron type club headwith any kind of cavity. There is a need in the art for a forged golfclub head with a cavity.

BRIEF DESCRIPTION OF THE DRAWINGS

To facilitate further description of the embodiments, the followingdrawings are provided in which:

FIG. 1 illustrates a flow diagram representation of one embodiment inwhich the exemplary golf club heads can be manufactured;

FIG. 2 illustrates a cross-sectional view of a first stage of a forgingmethod;

FIG. 3 illustrates a cross-sectional view of a second stage of a forgingmethod;

FIG. 4 illustrates a cross-sectional view of a third stage of a forgingmethod;

FIG. 5 illustrates a final golf club head with cavity.

Other aspects of the disclosure will become apparent by consideration ofthe detailed description and accompanying drawings.

For simplicity and clarity of illustration, the drawing figuresillustrate the general manner of construction, and descriptions anddetails of well-known features and techniques may be omitted to avoidunnecessarily obscuring the present disclosure. Additionally, elementsin the drawing figures are not necessarily drawn to scale. For example,the dimensions of some of the elements in the figures may be exaggeratedrelative to other elements to help improve understanding of embodimentsof the present disclosure. The same reference numerals in differentfigures denote the same elements.

DETAILED DESCRIPTION

Described herein is method of manufacturing an iron type golf club witha cavity, via a multi-stage forging process. The method comprises: roughforging solid block billet of a suitable metal to create an intermediateclub head body, hot pressing the intermediate club head to create acavity in the body, precision forging the intermediate club head tocreate a golf club body, and then attaching an insert within the cavity.The intermediate club head, formed through rough forging, comprises abent strike face, allowing a cavity to be formed in the rear body viahot pressing. The bent strike face of the intermediate club head is thenprecision forged. This bent strike face technique allows a manufacturerto create a forged golf club head body with a deep undercut cavity, froma single solid billet, as the bent strike face provides room to hotpress a cavity.

It is to be understood that the terms so used are interchangeable underappropriate circumstances such that the embodiments described hereinare, for example, capable of operation in sequences other than thoseillustrated or otherwise described herein. Furthermore, the terms“include,” and “have,” and any variations thereof, are intended to covera non-exclusive inclusion, such that a process, method, system, article,device, or apparatus that comprises a list of elements is notnecessarily limited to those elements but may include other elements notexpressly listed or inherent to such process, method, system, article,device, or apparatus.

The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,”“under,” and the like in the description and in the claims, if any, areused for descriptive purposes and not necessarily for describingpermanent relative positions. It is to be understood that the terms soused are interchangeable under appropriate circumstances such that theembodiments of the invention described herein are, for example, capableof operation in other orientations than those illustrated or otherwisedescribed herein. Furthermore, the term “rough forging” describes aforging technique wherein a block shaped billet is quickly formed into ageneral desired shape, with minimal tooling or machining.

Before any embodiments of the disclosure are explained in detail, it isto be understood that the disclosure is not limited in its applicationto the details of construction and the arrangement of components setforth in the following description or illustrated in the followingdrawings. The disclosure is capable of other embodiments and of beingpracticed or of being carried out in various ways.

In general, methods, apparatuses, and articles of manufacture associatedwith golf clubs, and in particular golf club heads are described herein.The methods, apparatuses, and articles of manufacture described hereinare not limited in this regard.

FIGS. 1-4 illustrate a method of manufacturing (multi-stage forgingprocess) a forged iron-type golf club head with a cavity. The method ofmanufacturing the iron-type golf club head with cavity comprises a roughforging stage, a hot-pressing stage, and a precision forging stage. Themethod of manufacturing a forged iron-type golf club head with cavity,illustrated in FIG. 5, can form a single iron-type golf club head withcavity, or a set of iron-type golf club heads with cavities.

A single iron-type golf club head with cavity, formed by the multi-stageforging process, can comprise a loft angle ranging between 60 degreesand 16 degrees. In many embodiments, the loft angle of the club head isless than approximately 60 degrees, the loft angle of the club head isless than approximately 59, degrees, the loft angle of the club head isless than approximately 58 degrees, the loft angle of the club head isless than approximately 57 degrees the loft angle of the club head isless than approximately 56 degrees, the loft angle of the club head isless than approximately 55 degrees, the loft angle of the club head isless than approximately 54 degrees, the loft angle of the club head isless than approximately 53 degrees, the loft angle of the club head isless than approximately 52 degrees, the loft angle of the club head isless than approximately 51 degrees, the loft angle of the club head isless than approximately 50 degrees, less than approximately 49 degrees,less than approximately 48 degrees, less than approximately 47 degrees,less than approximately 46 degrees, less than approximately 45 degrees,less than approximately 44 degrees, less than approximately 43 degrees,less than approximately 42 degrees, less than approximately 41 degrees,or less than approximately 40 degrees. Further, in many embodiments, theloft angle of the club head is greater than approximately 16 degrees,greater than approximately 17 degrees, greater than approximately 18degrees, greater than approximately 19 degrees, greater thanapproximately 20 degrees, greater than approximately 21 degrees, greaterthan approximately 22 degrees, greater than approximately 23 degrees,greater than approximately 24 degrees, or greater than approximately 25degrees.

Further still, the multi-stage forging process can form multipleiron-type golf club heads with cavities, wherein the multiple iron-typegolf club heads with cavities will comprise different lofts(aforementioned) to form a set of golf clubs (i.e., 3 iron, 4 iron, 5iron, 6 iron, 7 iron, 8 iron, 9 iron, PW). In some embodiments, themulti-stage forging process can form multiple iron-type golf club headswith identically sized cavities, and different lofts to form a set ofgolf clubs.

A. Rough Forging

Referring to FIG. 1, the multi-stage forging method, comprises fourstages: (1) a rough forging stage, in which intermediate club head body10 is formed from a solid block billet (not shown); (2) a hot-pressingstage, in which a cavity 58 is formed in the intermediate club headbody; (3) a precision forging stage wherein the intermediate club headbody 10 is formed into a final golf club head 80; (4) and an insert 110or filling is placed within the cavity 58 of the golf club head body 80.This multi-stage forging method allows a manufacturer to create a forgedgolf club head 80 with a deep undercut cavity 58, from a single solidbillet. In some embodiments, the multi-stage forging method can comprisea fifth stage (not shown), wherein a shaft and grip are attached to thegolf club head body 80, to form a golf club.

To begin the multi-stage forging method, a billeted material isprovided. The billet is forged into an iron type golf club head and canbe any one or more combination of the following: 8620 alloy steel, S25Csteel, carbon steel, maraging steel, stainless steel, stainless steelalloy, tungsten, aluminum, aluminum alloy, or any metal suitable forforging. The billet can be a solid block with no cavities or othermaterials attached to the billet. Further, the billet does notmonolithically encase any other material. The one or more materials canbe present on the surface of the billet, multiple surfaces of thebillet, or a corner of the billet.

In another embodiment, the solid billet can include two or more metals.The multi-metal billet is forged into an iron type golf club head andcan be any one or more combination of the following: 8620 alloy steel,S25C steel, carbon steel, maraging steel, stainless steel, stainlesssteel alloy, tungsten, aluminum, aluminum alloy, or any metal suitablefor forging. The multi-metal billet does not monolithically encase anyother material. The multi-metal billet can comprise a base metal, withat least one different metal on the surface of the billet, at least onedifferent metal on multiple surface of the billet, or at least onedifferent metal on a corner of the billet.

The next step of the multi-stage forging process is to forge the billetto into an intermediate club head 10. Referring to FIG. 2, theintermediate club head body 10 is formed from a solid block billet thatis rough forged by a first upper die 12 and a first lower die 14. Thefirst upper die 12 and first lower die 14 are shaped in a desired clubhead geometry. The solid block billet is heated to a desired temperaturebetween 700° C. and 1100° C., making the billet very malleable, thusallowing forging to occur. In some embodiments, the desired billettemperature for rough forging is between 700-725° C., 725-750° C.,750-775° C., 775-800° C., 800-825° C., 825-850° C., 850-875° C.,875-900° C., 900-925° C., 925-950° C., 950-975° C., 975-1000° C.,1000-1025° C., 1025-1050° C., 1050-1075° C., 1075-1100° C. In oneembodiment, the desired billet temperature for rough forging is between800-825° C.

Once the solid block billet is heated to a desired temperature, thefirst upper die 12 and first lower die 14 apply a desired pressure tothe billet, shaping the malleable billet to the shape of the desiredgeometry. The desired pressure that is applied to the billet by thefirst upper die 12 and the first lower die 14 is between 500 tons and800 tons (1 ton is equivalent to 2000 pounds force). In someembodiments, the desired pressure of the upper die 12 and lower die 14is between 500-525 tons, 525-550 tons, 550-575 tons, 575-600 tons,600-625 tons, 625-650 tons, 650-675 tons, 675-700 tons, 700-725 tons,725-750 tons, 750-775 tons, and 775-800 tons. In some embodiments, thedesired pressure of the upper die 12 and lower die 14 is between 600tons and 625 tons. The extreme pressure of the upper die 12 and lowerdie 14, quickly forms the malleable solid block billet to the desiredgeometry, thus maintaining the material and tensile properties of themetallic billet.

Referring to FIG. 2, is a cross-sectional view of the upper die 12 andlower die 14 forming the intermediate club head body 10, from the solidblock billet. The intermediate club head body 10 that is formed from therough forging comprises: a sole 16, a top rail 18, a strike face 20, aback wall 22 of the strike face 20, and a rear portion 24. The strikeface 20 has a heel end (not shown), a toe end (not shown), an upperregion 30, a lower region 32, and a strike plane 33. The strike plane 33is parallel to the lower region 32 of the strike face 20 and is thedesired plane that the strike face 20 will be bent to in a later step.The upper region 30 is opposite the back wall 22 of the strike face 20,while the lower region 32 is opposite the rear portion 24.

The rear portion 24 extends away from the strike face 20 and is adjacentthe sole 16. Further, the rear portion 24 comprises an upper edge 38.The upper edge 38 is approximately perpendicular to the strike plane 33and the lower region 32. The upper edge 38 provides a surface, or ledge,to form a cavity within, in a later step. The rear portion 24 furthercomprises a nonlinear outer periphery 40. The upper edge 38 spans theback wall of the strike face 22 from the heel end to the toe end. Thenonlinear outer periphery 40 connects the sole 16 to the upper edge 38of the rear portion 24.

The back wall 22 of the strike face 20, is adjacent the top rail 18 andthe upper edge 38, while parallel to the upper region 30 of the strikeface 20. The back wall 22 of the strike face 20 spans approximately fromthe heel end to the toe end.

The upper region 30 and lower region 32 of the strike face of theintermediate club head body 10, are divided by an intersection plane 34,wherein the intersection plane 34 is perpendicular to the lower region32 of the strike face 20 and the strike plane 33. The intersection plane34 is also approximately parallel to the upper edge 38 of the rearportion 24. The intersection plane 34 enables the forging of a cavity inthe rear portion 24 of the intermediate club head body 10. Theintersection plane 34 is the plane that which the strike face 20 is bentabout and is a bending point for creating the cavity 58 from the forgedbillet.

The intersection plane 34 runs approximately parallel to a ground plane35, wherein the ground plane 35 intersects the sole 16. In mostembodiments, the ground plane 35 is tangential to and parallel to thesole 16. In some embodiments, the ground plane 35 intersects the sole 16at an angle, not parallel to sole 16.

Further still, the intersection plane 34 intersects the strike face ofthe intermediate club head body 10, approximately bisecting theintermediate club head body 10, dividing the upper region 30 and thelower region 32. The intermediate club head body 10, further comprises aheight measured from the sole 16 to the top rail 18. In mostembodiments, the intersection plane 34 intersect the intermediate clubhead body 10 between 20-70% of the height of the club head body 10. Insome embodiments, the intersection plane 34 intersects the club headbody 10 at approximately 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%,65%, or 70% of the height of the club head body 10. In some embodiments,the intersection plane 34 intersects the club head body 10 betweenapproximately 20%-30%, 30%-40%, 40%-50%, 50%-60%, or 60%-70% of theheight of the club head body 10 or any other suitable percentage heightvalue in between those percentage height values, and can range from anyone of those percentage height values to any other one of thosepercentage height values.

A clearance angle 36 is formed between the intersection plane 34 and theupper region 30 of the strike face 20. The clearance angle 36 enablesenough space for a second upper die 54 and a second lower die 56 tocreate a cavity 58 in the intermediate club head 10 in a later step. Theclearance angle 36 can range between 1° and 89°. In some embodiments,the clearance angle 36 can range between 5° and 35°. In otherembodiments, the clearance angle 36 can range between 5°-11°, 9°-18°,and 13°-35°. In other embodiments, the clearance angle 36 can be 5°, 6°,7°, 8°, 9°, 10°, 11°, 12°, 13°, 14°, 15°, 16°, 17°, 18°, 19°, 20°, 21°,22°, 23°, 24°, 25°, 26°, 27°, 28°, 29°, 30°, 31°, 32°, 33°, 34°, and35°.

B. Cavity Formation

Referring to FIG. 3, the next step of the multi-stage forging method isthe cavity 58 formation in the intermediate club head body 10. Formationof the cavity 58 from the intermediate club head body 10 is accomplishedby one or more of the following processes: hot pressing, machining,milling, drilling, or machine punching. The embodiment in FIG. 3,illustrates the hot-pressing technique. The hot-pressing techniqueutilizes the second upper die 54 and the second lower die 56 (whereinthe second upper die 54 and second lower die 56 are different in shapefrom the first upper die 12 and first lower die 14 of the rough forgingstage) to precisely dimension a cavity 58 generally perpendicular to theupper edge 38 in the rear portion 24 of the intermediate club head body10. The second upper die 54 comprises a sharp geometry to penetratethrough the upper edge 38 of the rear portion 24, while the second lowerdie 56 holds the intermediate club head 10 at the desired clearanceangle 36, thus forming the cavity 58.

The necessary temperature required to hot press the cavity 58 in theintermediate club head body 10 can range between 700° C. and 1150° C. Inorder to avoid strain hardening of the metal during deformation, thisextreme heat is necessary for the hot-pressing process. If strainhardening occurs, the intermediate club head body 10 will become lessmalleable, making the cavity 58 harder to form. In some embodiments, thetemperature required to hot press the cavity 58 in the intermediate clubhead body 10 can range between 700-725° C., 725-750° C., 750-775° C.,775-800° C., 800-825° C., 825-850° C., 850-875° C., 875-900° C.,900-925° C., 925-950° C., 950-975° C., 975-1000° C., 1000-1025° C.,1025-1050° C., 1050-1075° C., 1075-1100° C., 1100-1125° C., 1125-1150°C. In one embodiment, the temperature required to hot press the cavity58 in the intermediate club head body 10 can range between 775° C. and800° C.

Once the intermediate club head body 10 is heated to a desiredtemperature, the second lower die 56 apply a desired pressure to theintermediate club head body 10 maintaining shape (strike face 20, bentabout an intersection plane 34, at a desired clearance angle 36). Thecavity 58 is then formed as the second upper die 54 applies a desiredpressure and the sharp geometry penetrates through the upper edge 38 andwithin the rear portion 24. The desired pressure that is applied to theintermediate club head body 10 by the second upper die 54 and the secondlower die 56 is between 500 tons and 800 tons (1 ton is equivalent to2000 pounds force). In some embodiments, the desired pressure of thesecond upper die 54 and second lower die 56 is between 500-525 tons,525-550 tons, 550-575 tons, 575-600 tons, 600-625 tons, 625-650 tons,650-675 tons, 675-700 tons, 700-725 tons, 725-750 tons, 750-775 tons,and 775-800 tons. In some embodiments, the desired pressure of the upperdie 54 and lower die 56 is between 675 tons and 700 tons. The extremepressure of the second upper die 54 and second lower die 56, quicklyforms the cavity 58 in the intermediate club head body 10, thusmaintaining the material and tensile properties of the metallicintermediate club head body 10.

The cavity 58 formed by the methods described above, includinghot-pressing, comprises a lower surface 60 and two interior surfacewalls 62. The cavity 58 further comprises a surface area and a volume,that can provide a surface and region to affix an insert to, in a laterstep.

Further, the cavity 58 comprises a cavity axis 69. The cavity axis 69passes through a nadir of the cavity 58 lower surface 60. The cavityaxis 69 exactly bisects the cavity 58 and is equidistant from the cavity58 interior surface walls 68. The cavity 58 can be hot-pressed at anangle 71, wherein the press angle 71 is measured from the cavity axis 69to the intersection plane 34. The press angle can range between 60° and90°. In some embodiments, the press angle 71 can range between 60°-65°,65°-70°, 70°-75°, 75°-80°, and 85°-90° or any other suitable press angle71 value in between those press angles 71 and can range from any one ofthose press angles 71 to any other one of those press angles 71. Inother embodiments, the press angle 71 can be 60°, 61°, 62°, 63°, 64°,65°, 66°, 67°, 68°, 69°, 70°, 71°, 72°, 73°, 74°, 75°, 76°, 77°, 78°,79°, 80°, 81°, 82°, 83°, 84°, 85°, 86°, 87°, 88°, 69°, or 90°. The pressangle 71, enables an insert to be affixed within the cavity 58 (in alater step) at a desired angle. Furthermore, the press angle 71 enablesa set of iron-type golf club heads with cavities to be formed, via themulti-stage forging method, with identical press angles 71, and/ordissimilar press angles 71.

Further still, the cavity 58 can have a substantially triangular,rectangular, square, semi-circular, parabolic, or trapezoidal crosssection. In some embodiments, the cavity 58 can comprise a differentcross-section at a toe end of the cavity 58 and the heel end of thecavity 58.

In some embodiments, the cavity 58 can have a volume of approximately0.8 cc, 1.0 cc, 1.25 cc, 1.5 cc, 1.75 cc, 2.0 cc, 2.25 cc, 2.5 cc, 2.75cc, 3.0 cc, 3.25 cc, 3.5 cc, 3.75 cc, 4.0 cc, 4.25 cc, 4.5 cc, 4.75 cc,5.0 cc, 5.25 cc, 5.5 cc, 5.75 cc, 6.0 cc, 6.25 cc, 6.5 cc, 6.75 cc, 7.0cc, 7.25 cc, 7.5 cc, 7.75 cc, 8.0 cc, 8.25 cc, 8.5 cc, 8.75 cc, 9.0 cc,9.25 cc, 9.5 cc, 9.75 cc, 10.0 cc, 10.25 cc, 10.5 cc, 10.75 cc, 11.0 cc,11.25 cc, 11.5 cc, 11.75 cc, 12.0 cc, 12.25 cc, 12.5 cc, 12.75 cc, 13.0cc, 13.25 cc, 13.5 cc, 13.75 cc, 14.0 cc, 14.25 cc, 14.5 cc, 14.75 cc,15.0 cc, 15.25 cc, 15.5 cc, 15.75 cc, 16.0 cc, or any other suitablevolume value in between those volume values, and can range from any oneof those volume values to any other one of those volume values. In oneembodiment, the volume of the cavity 58 is 4.25 cc. The volume of thecavity 58 can be substantially similar to the volume of an insert thatis affixed within the cavity 58.

In some embodiments, the cavity 58 can have a surface area rangingbetween approximately 3.00-4.00 cm², 4.00-5.00 cm², 5.00-6.00 cm²,6.00-7.00 cm², 7.00-8.00 cm², 8.00-9.00 cm², 10.00-11.00 cm²,11.00-12.00 cm², 12.00-13.00 cm², 13.00-14.00 cm², 14.00-15.00 cm²,15.00-16.00 cm², 16.00-17.00 cm², 17.00-18.00 cm², 18.00-19.00 cm²,19.00-20.00 cm², 20.00-21.00 cm², 21.00-22.00 cm², 22.00-23.00 cm²,23.00-24.00 cm², 24.00-25.00 cm², 25.00-26.00 cm², 26.00-27.00 cm²,27.00-28.00 cm², 28.00-29.00 cm², or 29.00-30.00 cm². In otherembodiments, the surface area of the cavity 58 can be any other suitablesurface area value in between those surface area values and can rangefrom any one of those surface area values to any other one of thosesurface area values. The surface area of the cavity 58 can besubstantially similar to the surface area of an insert that is affixedwithin the cavity 58.

In some embodiments, the cavity 58 can have a depth of approximately0.05 inches, 0.10 inches, 0.15 inches, 0.20 inches, 0.25 inches, 0.30inches, 0.35 inches, 0.40 inches, 0.45 inches, 0.50 inches, 0.55 inches,0.60 inches, 0.65 inches, 0.70 inches, 0.75 inches, 0.80 inches, 0.85inches, 0.90 inches, 0.95 inches, 1.0 inches or any other suitable depthvalue in between those depth values, and can range from any one of thosedepth values to any other on of those depth values. The depth of thecavity 58 can be substantially similar to a height of an insert that isaffixed within the cavity 58.

Following the cavity 58 formation in the intermediate club head body 10,a final precision forging stage is performed to straighten the clearanceangle 36 into a final golf club head.

C. Precision Forging

After the hot-pressing of the cavity 58 into the intermediate club headbody 10, the club head body 10 is precision forged, wherein the strikeface 20 is bent to a final angle 96, wherein the final angle 96 isformed between the intersection plane 34 and the strike face 20. Thefinal angle 96 is approximately between 88°-92° or 88°, 89°, 90°, 91°,or 92°, thereby aligning the upper region 30 with the lower region 32 ofthe club heady body 10. The intermediate club head body 10 is thereforeforged further into a final golf club head 80.

Referring to FIG. 4, this precision forging stage comprises a thirdupper die 82 and a third lower die 84, wherein the third upper die 82and third lower die 84 are shaped in a desired geometry (wherein thesecond upper die 54, the second lower die 56, the first upper die 12,and the first lower die 14 are different in shape from the third upperdie 82 and third lower die 84). The third upper die 82 and third lowerdie 84 apply a desired pressure to the intermediate club head body 10,bending the upper portion 30 of the strike face 20 to align with thelower portion 32 of the strike face 20 within the strike plane 33, thusbending the clearance angle 36 to a final angle 96 of approximately 90°to the intersection plane 36. In doing so, the intermediate club headbody 10 is forged into a final golf club head 80, as the strike face 20is now continuously straight and can function for its intended purposeof striking a golf ball.

The intermediate club head body 10, formed from the previous steps, mustbe heated to a desired temperature to bend the strike face 20 into thestrike plane 33 in order to carry out this stage of the method. Theintermediate club head body 10 is heated to a desired temperaturebetween 700° C. and 1100° C. In some embodiments, the desiredtemperature of the intermediate club head body 10 for precision forgingis between 700-725° C., 725-750° C., 750-775° C., 775-800° C., 800-825°C., 825-850° C., 850-875° C., 875-900° C., 900-925° C., 925-950° C.,950-975° C., 975-1000° C., 1000-1025° C., 1025-1050° C., 1050-1075° C.,1075-1100° C. In one embodiment, the desired temperature of theintermediate club head body 10 for rough forging is between 800-825° C.

Once the intermediate club head body 10 is heated to a desiredtemperature, the lower die 84 maintains the shape of the cavity andlower portion 32, while the third upper die 82 presses against the backwall 22. The third upper die 82 forces the upper portion 30 of theintermediate club head body 10 flush against the third lower die 84,thus aligning the upper portion 30 with the lower portion, and thereforebending the clearance angle 36 to approximately 90° to the intersectionplane 36. The desired pressure that is applied to the intermediate clubhead body 10 by the third upper die 82 and the third lower die 84 isbetween 500 tons and 800 tons (1 ton is equivalent to 2000 poundsforce). In some embodiments, the desired pressure of the third upper die82 and the third lower die 84 is between 500-525 tons, 525-550 tons,550-575 tons, 575-600 tons, 600-625 tons, 625-650 tons, 650-675 tons,675-700 tons, 700-725 tons, 725-750 tons, 750-775 tons, and 775-800tons. In some embodiments, the desired pressure of the third upper die82 and the third lower die 84 is between 675 tons and 700 tons. Theextreme pressure of the upper die 82 and the third lower die 84,maintains the form of the lower portion 32 and the cavity 58, whilepressing the upper region 30, in line with the lower region 32, and thusinto a functioning strike face 20. The strike face is then removed fromthe third upper die 82 and third lower die 84, and set to cool in a roomtemperature environment, until it is safe to the touch.

D. Insert Placement

Referencing FIG. 5, following the three stages of forging the final golfclub head 80, an insert 110 can be affixed to the interior surface wall62 and lower surface 60 of the cavity 58. In some embodiments, nothingis placed with the cavity 58. The insert 110 can be secured into thecavity 58 via adhesion, press-fitting, mechanical fastening, or anyother suitable methods of securing the insert 110. The insert 110 can bemade of one or more elastomers. For example, the insert 110 can be madeof nonferrous thermoplastic urethane, thermoplastic elastomericpolymer(s), hybrid plastics with a mix of ferrous particles or otheralloy ferrous particles mixed into polyurethane or other elastomericpolymers. In other embodiments, the insert 110 can be a metal such asaluminum, steel, tungsten, forms of beads in polymer, powder metal in asuspension cured in a polymer, or other suitable metals, such as whenthe insert 110 is sintered or machined.

Further, the insert 110 can occupy the entire cavity 58 or a percentageof the cavity 58.

The percentage of the cavity 58 that is occupied can range between 5%and 100%. In some embodiments, the percentage of the cavity 58 that isoccupied can range between 5%-15%, 15%-25%, 25%-35%, 35%-45%, 45%-55%,55%-65%, 65%-75%-85%, 85%-95%, 95%-100%. In one embodiment, thepercentage of the cavity 58 that is occupied ranges between 95%-100%.

In many embodiments, the insert 110 can have a weight thatadvantageously can be configured to reinforce the strike face 20, tobeneficially minimize undesirable impact vibration, and/or to establishor adjust the golf club swing weight during assembly. For example, theinsert 110 can have a mass of approximately 1.0 g to approximately 100g. For example, tuning element 150 can have a mass of approximately 1.0g, 2.0 g, 3.0 g, 4.0 g, 5.0 g, 6.0 g, 7.0 g, 8.0 g, 9.0 g, 10.0 g, 11.0g, 12.0 g, 13.0 g, 14.0 g, 15.0 g, 16.0 g, 17.0 g, 18.0 g, 19.0 g, 20.0g, 21.0 g, 22.0 g, 23.0 g, 24.0 g, 25.0 g, 26.0 g, 27.0 g, 28.0 g, 29.0g, 30.0 g, 35.0 g, 40.0 g, 45.0 g, 50.0 g, 55.0 g, 60.0 g, 65.0 g, 70.0g, 75.0 g, 80.0 g, 85.0 g, 90.0 g, 95.0 g, 100.0 g, or any othersuitable mass in between those mass values, and can range from any oneof those mass values to any other one of those distance values. Forexample, in some embodiments, the insert 110 can have a mass ofapproximately 1.0 g to approximately 30.0 g.

In several embodiments, the insert 110 can have a density ofapproximately 1.0 g/cc to approximately 20.0 g/cc. For example, theinsert 110 can have a density of approximately 1.0 g/cc, 1.5 g/cc, 2.0g/cc, 2.5 g/cc, 3.0 g/cc, 3.5 g/cc, 4.0 g/cc, 4.5 g/cc, 5.0 g/cc, 5.5g/cc, 6.0 g/cc, 6.5 g/cc, 7.0 g/cc, 7.5 g/cc, 8.0 g/cc, 8.5 g/cc, 9.0g/cc, 9.5 g/cc, 10.0 g/cc, 10.5 g/cc, 11.0 g/cc, 11.5 g/cc, 12.0 g/cc,12.5 g/cc, 13.0 g/cc, 13.5 g/cc, 14.0 g/cc, 14.5 g/cc, 15.0 g/cc, 15.5g/cc, 16.0 g/cc, 16.5 g/cc, 17.0 g/cc, 17.5 g/cc, 18.0 g/cc, 18.5 g/cc,19.0 g/cc, 19.5 g/cc, 20.0 g/cc, or any other suitable density value inbetween those density values, and can range from any one of thosedensity values to any other one of those density values.

In reference to FIG. 5, the final golf club 80, formed by theaforementioned manufacturing process, is a forged iron type golf clubhead with a cavity 58. The final golf club 80 comprises: a hosel 120, atop rail 122, a sole 124, a toe region 126, a heel region 128, a rear130, a strike face 20 (not shown), a cavity 58, and an insert 110.

E. Method of Manufacturing a Set of Golf Clubs and a Forged Set of Clubswith Similar Sized Cavities

Referring to FIG. 1, the multi-stage forging method, comprises fourstages: (1) a rough forging stage, in which intermediate club head body10 is formed from a solid block billet (not shown); (2) a hot-pressingstage, in which a cavity 58 is formed in the intermediate club headbody; (3) a precision forging stage wherein the intermediate club headbody 10 is formed into a final golf club head 80; (4) and an insert 110or filling is placed within the cavity 58 of the golf club head body 80.This multi-stage forging method allows a manufacturer to create a forgedgolf club head 80 with a deep undercut cavity 58, from a single solidbillet. However, in this embodiment, the multi-stage forging methodcomprises a fifth stage (not shown), wherein a shaft and grip areattached to the golf club head body 80, to form a golf club. Themulti-stage forging process is then repeated to form multiple iron-typegolf club heads with cavities, wherein the multiple iron-type golf clubswith cavities will comprise different lofts (aforementioned) to form aset of golf clubs (i.e., 3 iron, 4 iron, 5 iron, 6 iron, 7 iron, 8 iron,9 iron, PW).

In some embodiments, the multi-stage forging process can form multipleiron-type golf club heads with identically sized cavities, and differentlofts to form a set of golf clubs. With identically sized cavities, theinserts that are affixed to each golf club head, all have an exact samevolume, but can have varying densities and therefore varying masses.This variability allows the inserts for each golf club head of the golfclub set to have different swing weights and/or different CG locations.Furthermore, this make the manufacturing of the inserts more efficient,since only the material (therefore changing the density) of the insertneeds to be changed, in order to change the weighting of the insert, foreach club head. Inserts are produced at different weights in order toaccount for manufacturing tolerances (i.e., if a golf club head issupposed to weight 425 grams, but only weighs 415 grams, then a 10 gramweight can be added to the golf club head cavity).

The aforementioned method of manufacturing produces can produce of setof forged iron-type golf clubs with similar sized cavities. In referenceto FIG. 5, the final golf club head 80 formed by the method ofmanufacturing comprises a hosel 120, a top rail 122, a sole 124, a toeregion 126, a heel region 128, a rear 130, a strike face 20 (not shown),a cavity 58, an insert 110, a shaft (not shown), and a grip (not shown).The set of forged iron-type golf clubs can comprise 2 golf clubs, 3 golfclubs, 4 golf clubs, 5 golf clubs, 6 golf clubs, 7 golf clubs, 8 golfclubs, 9 golf clubs, or 10 golf clubs.

Each golf club of the forged iron-type golf club set can comprise cavity58 having a volume of approximately 0.8 cc, 1.0 cc, 1.25 cc, 1.5 cc,1.75 cc, 2.0 cc, 2.25 cc, 2.5 cc, 2.75 cc, 3.0 cc, 3.25 cc, 3.5 cc, 3.75cc, 4.0 cc, 4.25 cc, 4.5 cc, 4.75 cc, 5.0 cc, 5.25 cc, 5.5 cc, 5.75 cc,6.0 cc, 6.25 cc, 6.5 cc, 6.75 cc, 7.0 cc, 7.25 cc, 7.5 cc, 7.75 cc, 8.0cc, 8.25 cc, 8.5 cc, 8.75 cc, 9.0 cc, 9.25 cc, 9.5 cc, 9.75 cc, 10.0 cc,10.25 cc, 10.5 cc, 10.75 cc, 11.0 cc, 11.25 cc, 11.5 cc, 11.75 cc, 12.0cc, 12.25 cc, 12.5 cc, 12.75 cc, 13.0 cc, 13.25 cc, 13.5 cc, 13.75 cc,14.0 cc, 14.25 cc, 14.5 cc, 14.75 cc, 15.0 cc, 15.25 cc, 15.5 cc, 15.75cc, 16.0 cc, or any other suitable volume value in between those volumevalues, and can range from any one of those volume values to any otherone of those volume values. In one embodiment, the volume of the cavity58 is 4.25 cc. The volume of the cavity 58 can be substantially similarto the volume of an insert that is affixed within the cavity 58. Thevolume can also be approximately identical for each golf club of theforged iron-type golf club set.

F. Benefits

The enclosed manufacturing process is an improvement over the currentindustry standard. The multi-stage forging process utilizes a dual stageforging process, in which an intermediate club head 10 is formed with astrike face 20 that is bent at a clearance angle 36, enabling a cavity58 to be hot pressed opposite of the strike face 20. The strike face 20is then bent back into a functional strike face 20, and a final golfclub head 80 is created. This bent strike face 20 technique allows amanufacturer to create a forged golf club head body 80 with a deepundercut cavity 58, from a single solid billet.

By creating an entirely forged golf club head 80, with a deep undercutcavity 58, a tighter grain structure of the golf club head is achieved.With a tighter grain structure, the durability of the golf club head 80is improved. Forging the golf club head 80 with a deep undercut cavity58 from the billet process, allows a more durable cavity style iron thancurrent cast cavity irons, because of a tighter and more consistentgrain structure.

Further, this multi-stage forging method is more repeatable than currentcasting methods. Current casting methods require manual machiningprocesses to remove excess material and clean the shape of the clubhead, whereas the forging method requires little to no machining. Thus,the forging process is more repeatable since there is less uncertaintyinvolved from hand machining techniques. Furthermore, with lessmachining processes involved in the golf club head production, theenclosed invention lowers the overall cost of producing a premium golfclub head with an undercut cavity.

The golf club head created from this multi-stage forging method, iscomparable in feel and performance to a casted golf club head of similargeometry. Since the forged iron comprises a stronger composition, thestrike face is able to be made thinner, thereby increasing theflexibility of the strike face. The forged iron thus increases ballspeed and workability (shot bend) over a casted golf club head ofsimilar geometry, while maintaining or improving spin rates, soundcharacteristics, and feel characteristics.

Replacement of one or more claimed elements constitutes reconstructionand not repair. Additionally, benefits, other advantages, and solutionsto problems have been described with regard to specific embodiments. Thebenefits, advantages, solutions to problems, and any element or elementsthat may cause any benefit, advantage, or solution to occur or becomemore pronounced, however, are not to be construed as critical, required,or essential features or elements of any or all of the claims.

As the rules to golf may change from time to time (e.g., new regulationsmay be adopted or old rules may be eliminated or modified by golfstandard organizations and/or governing bodies such as the United StatesGolf Association (USGA), the Royal and Ancient Golf Club of St. Andrews(R&A), etc.), golf equipment related to the apparatus, methods, andarticles of manufacture described herein may be conforming ornon-conforming to the rules of golf at any particular time. Accordingly,golf equipment related to the apparatus, methods, and articles ofmanufacture described herein may be advertised, offered for sale, and/orsold as conforming or non-conforming golf equipment. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

While the above examples may be described in connection with an irongolf club, the apparatus, methods, and articles of manufacture describedherein may be applicable to other types of golf club such as awedge-type golf club. Alternatively, the apparatus, methods, andarticles of manufacture described herein may be applicable other type ofsports equipment such as a hockey stick, a tennis racket, a fishingpole, a ski pole, etc.

Moreover, embodiments and limitations disclosed herein are not dedicatedto the public under the doctrine of dedication if the embodiments and/orlimitations: (1) are not expressly claimed in the claims; and (2) are orare potentially equivalents of express elements and/or limitations inthe claims under the doctrine of equivalents.

Various features and advantages of the disclosure are set forth in thefollowing claims.

Clause 1: A method of manufacturing a golf club head, the methodcomprising: providing a billet of at least one material; forming thebillet into an intermediate club head body by means of forging, whereinthe intermediate body comprises: a sole, a top rail, a strike face, aback wall of the strike face, and a rear portion, wherein the rearportion of the body has an upper edge and a nonlinear outer periphery,wherein the strike face comprises an upper region, and a lower region,wherein the upper region and lower region of the strike face are dividedby an intersection plane, wherein the intersection plane isperpendicular to the lower region of the strike face, wherein the strikeface is formed at a clearance angle, wherein the clearance angle ismeasured from the upper region of the strike face to the intersectionplane; wherein the clearance angle of the strike face is between 5° and35°; forming a cavity in the rear portion of the body by means ofhot-pressing; bending the strike face to a final angle, by means offorging, into a substantially planar surface arranged for impacting agolf ball, to form the golf club head having a cavity; and wherein thefinal angle is 90°.

Claus 2: The method of manufacturing the golf club head of clause 1,wherein the golf club head comprises a sole, a top rail, a strike face,a back wall of the strike face, a toe end, a heel end, and a rearportion; wherein the rear portion of the body has an upper edge and anonlinear outer periphery; wherein the strike face has a heel end, a toeend, an upper region, and a lower region; wherein the upper region andlower region of the strike face are divided by an intersection plane;wherein the intersection plane is perpendicular to the lower region ofthe strike face.

Clause 3: The method of manufacturing the golf club head of clause 1,wherein the intersection plane is perpendicular to the lower region ofthe strike face and the strike plane.

Clause 4: The method of manufacturing the golf club head of clause 1,wherein the intersection plane intersects the golf club head atapproximately 40-50% of a height of the club head; wherein the height ofthe club head is measured from the sole of the golf club head to the toprail of the golf club head.

Clause 5: The method of manufacturing the golf club head of clause 1,wherein the cavity formed by the hot-pressing stage comprises a volumeranging between 0.2 in³ and 0.4 in³.

Clause 6: The method of manufacturing the golf club head of clause 1,further comprising: fixing an insert within the cavity.

Clause 7: The method of manufacturing the golf club head of clause 6,wherein the insert can be fixed within the cavity via adhesion,press-fitting, mechanical fastening, or any other suitable methods ofsecuring the insert.

Clause 8: The method of manufacturing the golf club head of clause 7,wherein a percentage of the cavity that is occupied by the insert rangesbetween 95%-100%.

Clause 9: The method of manufacturing the golf club head of clause 1,wherein the golf club head comprises a loft angle between 19° and 60°

Clause 10: The method of manufacturing the golf club head of clause 1,wherein the billet does not monolithically encase any other material.

Claus 11: The method of manufacturing the golf club head of clause 2,wherein the cavity of the golf club head extends in a direction from theheel end to the toe end.

Clause 12: The method of manufacturing the golf club head of clause 2,wherein the cavity formed by the hot-pressing stage further comprises acavity axis; wherein the cavity axis passes through a nadir of thecavity; wherein the cavity axis exactly bisects the cavity and isequidistant from the cavity interior surface walls.

Clause 13: The method of manufacturing the golf club head of clause 12,wherein the cavity formed by the hot-pressing stage further comprises apress angle; wherein the press angle is measured from the cavity axis tothe intersection plane.

Clause 14: The method of manufacturing the golf club head of clause 12,wherein the press angle ranges between 60°-90°.

Clause 15: The method of manufacturing the golf club head of clause 1,wherein the cavity formed by the hot-pressing stage further comprises asubstantially triangular, rectangular, square, semi-circular, parabolic,or trapezoidal cross section.

Clause 16: The method of manufacturing the golf club head of clause 6,wherein the insert that is fixed within the cavity comprises a massranging between 1.0 g and approximately 30.0 g.

Clause 17: The method of manufacturing the golf club head of clause 16,wherein the insert that is fixed within the cavity comprises a densityranging between 1.0 g/cc and approximately 20.0 g/cc.

Clause 18: The method of manufacturing the golf club head of clause 10,wherein the billet comprises one or more of the following metals: 8620alloy steel, S25C steel, carbon steel, maraging steel, stainless steel,stainless steel alloy, tungsten, aluminum, aluminum alloy, or any metalsuitable for forging.

Clause 19: The method of manufacturing the golf club head of clause 10,wherein the billet comprises two or more of the following metals: 8620alloy steel, S25C steel, carbon steel, maraging steel, stainless steel,stainless steel alloy, tungsten, aluminum, aluminum alloy, or any metalsuitable for forging.

Clause 20: The method of manufacturing the golf club head of claim 10,wherein the billet comprises two or more metals, wherein at least one ofthe metals is 8620 alloy steel and at least one of the metals istungsten.

What is claimed is:
 1. A forged golf club head comprising: a club headbody comprising a sole, a top rail, a strike face, a back wall of thestrike face, and a rear portion; wherein the strike face comprises aheel end, a toe end, an upper region, and a lower region; wherein therear portion of the body has an upper edge and a nonlinear outerperiphery; a cavity formed between the rear portion and the back wall ofthe strike face; wherein the cavity comprises a volume between 3.5 ccand 6.5 cc; wherein the club head body is forged from a single solidbillet; and wherein the club head body comprises a tighter grainstructure than a similar cast club head body.
 2. The forged golf clubhead of claim 1, wherein the single solid billet comprises at least twometals.
 3. The forged golf club head of claim 1, wherein the singlesolid billet comprises one or more of the following metals: 8620 alloysteel, S25C steel, carbon steel, maraging steel, stainless steel,stainless steel alloy, tungsten, aluminum, aluminum alloy, or any metalsuitable for forging.
 4. The forged golf club head of claim 1, whereinthe single solid billet comprises two or more of the following metals:8620 alloy steel, S25C steel, carbon steel, maraging steel, stainlesssteel, stainless steel alloy, tungsten, aluminum, aluminum alloy, or anymetal suitable for forging.
 5. The forged golf club head of claim 1,wherein the single solid billet comprises two or more metals, wherein atleast one of the metals is 8620 alloy steel and at least one of themetals is tungsten.
 6. The forged golf club head of claim 1, wherein thesingle solid billet does not monolithically encase any other material.7. The forged golf club head of claim 1, further comprising an insertfixed within the cavity.
 8. The forged golf club head of claim 7,wherein the insert occupies between 95% and 100% of the volume of thecavity.
 9. The forged golf club head of claim 1, wherein the cavity ofthe golf club head extends in a direction from the heel end to the toeend.
 10. The forged golf club head of claim 1, wherein the cavitycomprises a substantially triangular, rectangular, square,semi-circular, parabolic, or trapezoidal cross section.
 11. The forgedgolf club head of claim 7, wherein the insert that is fixed within thecavity comprises a mass ranging between 1.0 g and approximately 30.0 g.12. The forged golf club head of claim 7, wherein the insert that isfixed within the cavity comprises a density ranging between 1.0 g/cc andapproximately 20.0 g/cc.
 13. The forged golf club head of claim 7,wherein the insert can be fixed within the cavity via adhesion,press-fitting, mechanical fastening, or any other suitable method ofsecuring the insert.
 14. The forged golf club head of claim 13, whereinthe insert is affixed to an interior surface wall of the cavity.
 15. Theforged golf club head of claim 1, wherein the cavity extends in adirection from the heel end to the toe end.
 16. The forged golf clubhead of claim 1, wherein the club head body comprises a loft anglebetween 19° and 60°.
 17. The forged golf club head of claim 1, whereinthe cavity is formed through one or more processes selected from thegroup consisting of hot pressing, machining, milling, drilling, andmachine punching.
 18. The forged golf club head of claim 1, wherein thecavity comprises a depth between 0.25 inches and 1.0 inch.
 19. Theforged golf club head of claim 7, wherein the insert is formed of one ormore materials selected from the group consisting of a thermoplasticurethane, a thermoplastic elastomeric polymer, a hybrid plastic, anelastomeric polymer, aluminum, steel, and tungsten.
 20. The forged golfclub head of claim 1, further comprising: a ground plane tangential andparallel to the sole; an intersection plane parallel to the ground planeand perpendicular to the lower region of the strike face; a cavity axispassing through a nadir of the cavity; a press angle measured betweenthe cavity axis and the intersection plane; wherein the cavity axisexactly bisects the cavity and is equidistant from interior surfacewalls of the cavity; and wherein the press angle is between 60° and 90°.